Modular Bulkhead System for Hand-Carried Fan Array Retrofitting
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Solution Overview
Problem
The existing HVAC industry practices require the removal and replacement of entire air handling units to replace malfunctioning fan systems, which is costly and labor-intensive, often necessitating the use of cranes due to the weight and size constraints of air handling units.
Innovation Solution
A modular bulkhead system that allows for the retrofitting of new fan arrays within existing air handling units by providing a modular bulkhead wall and structural frame that can be hand-carried and installed, enabling the attachment of fans and connection to power and control systems without the need for crane-assisted removal and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire air handling unit is removed and replaced to replace a malfunctioning fan system, then the fan system replacement is complete, but the cost increases substantially and crane equipment is required
Solution Approach 1:
The bulkhead is divided into multiple removable panels that can be individually accessed and installed. This segmentation allows technicians to work on the fan system without removing the entire air handling unit, reducing installation complexity and cost while avoiding the need for crane equipment.
2Ease of repair
If the entire air handling unit is removed and replaced, then the fan system is replaced, but the installation time and cost increase substantially
Solution Approach 1:
The bulkhead panels can be quickly removed and reinstalled, allowing fan system replacement to be completed in a fraction of the time required for full air handling unit replacement. This segmentation enables rapid access to the fan system without time-consuming complete unit removal and reinstallation.
3Strength
If air handling units are designed with heavy cabinets for structural integrity, then the units are durable, but they require crane equipment for removal and replacement
Solution Approach 1:
The bulkhead panels are extracted as separate, lightweight components from the overall air handling unit structure. This allows the heavy cabinet to remain in place for structural integrity while the lightweight panels enable easy manual installation and fan system replacement without requiring crane equipment.
4Ease of manufacture
If the modular bulkhead system is used for retrofitting, then cost savings are achieved, but the bulkhead must be designed with removable panels
Solution Approach 1:
The bulkhead is designed with segmented removable panels that, while adding some design complexity, enable cost-effective retrofitting by allowing fan system replacement without full air handling unit replacement. The modular design facilitates easier maintenance and repair operations.
Data Source
AI summary
A structural support system for a fan array system. The system allows for a modular bulkhead wall to be customized and installed within a cabinet of an air handling unit. The modular bulkhead wall comprises one or more intermediate bulkhead stiffening elements that enable the modular bulkhead wall to support the fan array system.